Related Manuals for Welger RP 202 CLASSIC
Summary of Contents for Welger RP 202 CLASSIC
- Page 1 RP 202 / RP 302 RP 220 / RP 320 WELGER www.welger.com RP 320 MASTER 1741-113 1753-27 Operating manual from year of manufacture 2004 1742.99.03.05 02.04...
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Page 3: Table Of Contents
Reproduction prohibited - all rights reserved. Design and construction subject to alterations. The illustrations shown are non-binding for model, form and equipment. 2000 by 2004 by Welger Maschinenfabrik GmbH, Wolfenbüttel. Made in Germany. Maschinenfabrik GmbH Gebrüder-Welger-Straße 3 •... - Page 5 Handover Declaration Please fill in this form when the machine is handed over and return it to the distributor. No warranty applications can be processed until this form is received. Welger Maschinenfabrik GmbH Abteilung T.S. (Technical Support) Postfach 1965 D-38289 Wolfenbüttel (1) Handover Date RP ....
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Page 7: Model Overview
Conveyor bottom HYDROFLEXCONTROL spring loaded a. hydr. actuated VARIOTWIN Twine wrapping Wrapping VARIONET Net wrapping BALERCONTROL E Control BALERCONTROL III Table 1 = Standard equipment = Special equipment WELGER RP 202 • RP 220 • RP 302 • RP 320... -
Page 8: Your Safety
Warning! The baler is inherently dangerous even if all the points listed above are followed exactly. Therefore always take care when working with the baler to avoid endangering yourself or other people! WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 9 The noise level generated by WELGER balers, measured at the driver's head height with the tractor window open, is less than 70 dB(A) under normal working conditions. The combined noise level generated by the baler and tractor primarily depends on the level of tractor noise (radios are an additional source of noise).
- Page 10 The shut-off valve may only be actuated from the right side of the machine. Return the valve to its original position after completing maintenance and installation/assembly work (fig. 2). fig. 2 0387-35 fig. 3 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 11 Before you step on the maintenance platform: Stop the machine, switch off power-take- off shaft and motor engine and wait until the machine has stopped. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 12 Spare part No.: 0389.94.00.00 Always switch off the engine and remove the ignition key before starting any maintenance and repair work. Spare part No.: 0388.25.00.00 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 13 The accumulator is under gas pressure or oil pressure. Depressurise the hydraulic system before removal and repairs. Spare part No.: 0387.37.00.00 Activate the tailgate safeguard before entering the roll chamber. Spare part No.: 0387.34.00.00 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 14 Spare part No.: 0387.35.00.00 Maximum permissible hydraulic pressure The machine may only be connected to a hydraulic system which supplies a maximum oil pressure of 210 bar. Spare part No.: 0387.36.00.00 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 15 In particular, it has to be taken into account that any additionally installed electrical and electronic components comply with the EMC Directive 89/336/EEC in the respective current version and that they are CE labeled. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 16 Model-dependent maximum speeds limits have been exclusively specified in this operating manual. Current relevant national regulations, which may differ from manufacturers instructions, are always required to be observed. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 17 Furthermore, the national regulations from the country of use are to be observed. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 18 Max. imposed load on the drawbar eye. The open-type hitch on the tractor must be approved for this imposed load. Permissible type-related maximum speed of the machine. National regulations can specify a lower speed! Internal control number WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 19 Meaning Drawbar type (designation): D7 or D8 Official mark of conformity Permissible, maximum total weight of the machine Permissible maximum imposed load (D7: 400 kg; D8: 800 kg) WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 20: Component Overview
Pick up unit Net wrapping* BALERCONTROL III - Control panel* Bale ejector* BALERCONTROL E - Control panel* Tailgate Cutting device* Lock Floor flap* Chain wheels for roller drive Twine wrapping* WELGER RP 202 • RP 220 • RP 302 • RP 320... -
Page 21: Putting Into Operation
• Apply the parking brake before detaching the machine from the tractor (turn crank clockwise). WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 22 4.1.1. Drawbar configuration (all dimensions in [mm]) fig. 10 fig. 11 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 23 • Firmly tighten all fastening screws and nuts. fig. 13 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 24 RP 202 CLASSIC Bracket fig. 13 450 Nm RP 202 SPECIAL RP 220 RP 302 RP 320 Drawbar eye fig. 14, item 1 400 Nm Table 2: Tension moment WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 25 2) The upper part of the tow hitch can be dismantled to comply with dimension c. Dimensions are in millimetres Table 3: Dimensions, location and support load of the tow hitch WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 26 Undo the clamping cone and pull it out of the clutch hub. If that cannot be done by hand, the clamping cone can also be driven out from the other side with the help of a pin punch. 1742-4 fig.18 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 27 21 permissible rpm and direction of rotation of the machine (540 min Only start the pto shaft at idling speed! WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 28 Hydraulic switch with the functions RP 220 w. CD double-acting • floor flap* RP 320 w. CD • pick up unit • cutting device* CD = Cutting Device* WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 29 As a result, the useful service life is limited. According to the "Safety Regulations for Hydraulic Hoses", a service life of six years should not be exceeded! WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 30 23 The correct polarity of the power supply on the tractor must not be changed, since otherwise the electronic control unit might be damaged (fig. 24). fig. 24 WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 31: Twine Wrapping
Use the additional guide eyes between the deflection rollers (2) and the pair of eyes (3). 5. The twines shall not touch each other. 6. For continuation go to fig. 27. WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 32 CLASSIC and SPECIAL RP 220 / RP 320 FARMER fig. 25 Threading-in diagram for machines with „ BALERCONTROL III” RP 220 / RP 320 MASTER / PROFI fig. 26 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 33 5. Tension both sets of twine once they have been threaded. fig. 27 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 34 Note: The permitted thread tension is exceeded when the twine breaks in the vicinity of the guide rollers [8] (fig. 27). fig. 28 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 35 Switching angle (3) towards the variator disk → more end windings on the edge of the bale Switching angle (3) towards the machine centre → less end windings on the edge of the bale fig. 31 WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 36: Net Wrapping
• Remove cotter pin from net tensioner and pull net tensioner to the front again. • Tighten handwheel [1]. fig. 34 fig. 35 WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 37 10 cm. • Move the net tensioner [3] forward into its working position. fig. 37 fig. 38 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 38 However, the bales must still be held together securely. With very smooth material and a high pressing density, a greater amount of net may be needed. fig. 40 WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 39: Cutting Device
This activates at a factory set pressure limit. This is also the pressure available for moving in the blades. Depending on the situation, the hydraulic pressure may not necessarily suffice if fig.43 the blade grooves are blocked. fig.44 WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 40 Finally, the blades must definitely be once again moved completely in and out without having to depress the cutting device button . Otherwise, the machine overload will result in a cancellation of the warranty! WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 41 The shut-off valve (fig. 45) is only opened for moving the blades in and out. During normal operation the shut-off valve must always remain closed (position “0” in fig. 46). WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 42 After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty! 0387.16.00.00 fig. 49 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 43 2. Set the connected tractor control valve to „Lower“ for 5–10 s approx.. Tip: In order to ensure free movement of the individual blades, switch the cutting device on and off several times each day. fig. 51 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 44 It is absolutely necessary that finally the cutting device is once again lowered and raised (see points 2 and 3). Otherwise machine overload will result in cancellation of the warranty! fig. 54 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 45 After setting back the ball valve, it is absolutely necessary that the blades are once again moved in and out. Otherwise, the machine overload will result in a cancellation of the warranty! 0387.16.00.00 fig. 56 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 46 (fig. 58). Note: Removed blades should be replaced by dummy blades* in order to prevent the slots from becoming blocked. (Part no. 1724.55.12.37) fig. 58 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 47 Pay attention that the hardened cutting edges are not drawn when grinding. A grinder is available as a spare part. (Part no. 0980.70.14.00) WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 48: Field Use
The windrow width should be as follows: Pick-up unit width 1.50 m 2.00 m 2.25 m Optimal 1.30 m 1.40 m 1.50 m windrow width (approx.) WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 49 [2] with the desired hole (fig. 63); secure the support wheels once again with the spring retainer. Provide the same setting on both sides. fig. 63 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 50 When using the baler, both support wheels must be installed at all times. fig. 66 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 51 (at the tractor) does not exceed 80°. Otherwise there is a danger of breakage during operation and at rest. richtig falsch correct wrong correct faux fig. 68 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 52 3. Finally, screw on the wing nut once again. fig. 69 RP 220 • RP 320 MASTER / PROFI (See separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“) WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 53 RP 220 • RP 320 MASTER / PROFI A short signal tone informs the tractor driver that the tailgate is fully locked. WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 54: Wrapping
(LTC fig. 70 Bottom row: daily counter (DLC) can be reset; buzzer Pre-selected bale density reached (on back side) DLC = Daily Counter LTC = Life Time Counter WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 55 Check the net is running by the detection pulley (fig. 72). As fig. 72 soon as the detection pulley stops the wrapping process is finished. • Open the tailgate and eject the bale. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 56 • In order to tightly bind the start of the twine, quickly supply extra crop shortly after the wrapping process begins. • After finishing the wrapping process, eject the bales at normal speed. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 57 Button <NET> Trigger the net wrapping by hand Button Trigger the twine wrapping by hand <TWINE> 1724-37 fig. 73 Buzzer (on Pre-selected bale density reached back side) WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 58 The following two pages show the relevant operating steps and the associated display on the control panel for each type of wrapping: WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 59 8 sec. after depressing button. Stop driving tractor After completion of the twine wrapping (twine movement sensors indicate stoppage): A signal sounds. Then: Open tailgate with tractor control valve. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 60 More crop can be once again added. After completion of the net wrapping (net cutting knife was operated): A signal sounds, Then: Open the tailgate using the tractor control valve. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 61 „0“. The bar graph display for the bale density has dropped to More crop can be once again „0“. added. More crop can be once again added. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 62 “Net cutting knife tensioned?” If the button <NET> is depressed once more, wrapping starts again. Before beginning wrapping, check whether the net cutting knife has been reset. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 63 If the ground is uneven, the bale may start to roll or tip over onto its side. Employ suitable measure to eliminate this risk. All persons must move away from the bale’s possible movement area. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 64 1724-38 fig. 77 Before restarting the baler, remove the crank lever and close up all protective guards! WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 65 6. If the cutting function is required, the blades must be swung in once again. The symbol for „cutting device active“ appears in the display. fig. 80 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 66 6. To enable the hydro accumulators to fill: actuate the control valve for another 5 s. approx. after the blades have moved fig. 82 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 67 When the bottom flap is being closed, the blades move automatically to working position. If you want to work without blades, they must subsequently be moved to home position again: see chapter 7. Cutting Device! WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 68 ......buttondepressed. Control unit Serial No......SW version ......Press button several times until "Systeminfo" appears in the SW date ......display. Memory ......WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 69 Disconnect the power supply between the tractor and baler. Be careful of heat generated at welding points; detach any potentially sensitive components (cables, sensors etc) before welding. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 70 After approx. 4 seconds the final display appears. fig. 83 11.4. Menu structure (See separate operating manual „BALERCONTROL III with Graphic Display for RP 220/RP 320“) WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 71: Maintenance / Settings
Any work on the clamping elements [3] may only be carried out by instructed expert personnel. fig. 84 WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 72 If there is excessive wear on one side of the brake disc lining [4], undo the lock nut [5], turn the screw [6] until the brake fig. 85 linings are parallel again and re-apply the lock nut [6]. fig. 86 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 73 • Interrupt the provisional electrical connection for the net or twine wrapping unit if the vehicle lighting is to be switched on for a long duration, e.g. when driving on the road. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 74 Left clearance sensor, yellow (L) Sensor, left twine run (2) Right clearance sensor, yellow (R) Sensor, net cutting knife (N) 1) Only for models with a cutting device WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 75 ➜ Rest position Bottom flap ➜ closed closed open closed closed ➜ Pick-up unit Symbol: = voltage at solenoid valve ➜ = line is pressurised WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 76 RP 220 FARMER • RP 320 FARMER with cutting unit and without swivel floor fig. 91 Note: During baler operation, the changeover valve "U" must always point towards the machine centre. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 77 During operation, the shut-off valve [1] must be closed, otherwise the floor may lower itself. • During baler operation, the changeover valve "U" must always point towards the machine centre. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 78 2.25 m pick-up unit only (see Table 1) fig. 93 Note: During baler operation, the changeover valve "U" must always point towards the machine centre. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 79 1740.82.14.10 • Tailgate clearance, right MASTER only possible using special Clearance tools sensor PROFI • Tailgate clearance, left (yellow) Part No.: 0980.70.01.00 ∅ 20 mm and: 1740.82.14.10 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 80 • In DIAGNOSIS / VOLTAGE, check the operating voltage − Voltage drop not greater than 1 - 2 Volts ..........− Voltage under load not less than 11 volts ..........WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 82 • Insert tank sieve and screw tank lid down again. Subsequently: • Check oil level in oil tank. Warning! Never use for cleaning: Tri, Per, Methanol, Acetone or other polar, organic solvents. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 83 Grease type: see chapter „12.13. Lubrication chart“. If necessary: Refill grease: • Clean filling nipple on lubricant tank. fig. 95 • Fill lubricant tank via the filling nipple using a lever-type grease gun. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 84 Locking hook disc spring Warning: do not change sensor settings! Twine guide eyes Lightly grease chafe mark Gearbox is labelled on the top side with the letters "V V" WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 85 SAE 90 Machine oil - - - Multi-pupose grease Gleitmo 810 Multi-pupose grease Multi-pupose grease according NLGI-Class 2, with high-pressure additive, without solids Table 4: Specification of lubricants WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 86 For correct setting, the longitudinal section of the operating rollers should just about gently strike the dividing plates. Finally tighten the screws once again. fig. 97 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 87 The chains of the roller drives must be tensioned so far that the spring plates are approximately flush with the measuring angles (fig. 99 and fig. 100). fig. 99 fig. 100 WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 88 • Remove all crop residues from the machine. • Thoroughly lubricate all bearings. • Remove, grind and reinstall cutter blades. • Grease wrapping unit. • Check and – if necessary – adjust air pressure. WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 89 25 km/h 500/60-22.5 Impl. 8 PR 40 km/h 1,5 bar 1,5 bar 16 È 6.50-8 4 PR pick-up unit support wheels: 2,0 bar WELGER RP 202 • RP 220 • RP 302 • RP 320...
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Page 90: Technical Data
[kg] Model-dependent permissible maximum speed limit – CLASSIC, SPECIAL 25 km/h – FARMER, MASTER, PROFI, without brakes 25 km/h FARMER, MASTER, PROFI, – 40 km/h with air brakes WELGER RP 202 • RP 220 • RP 302 • RP 320... - Page 91 1) Only 1 net roll can be inserted if twine wrapping is installed 2) Pay attention to applicable national road traffic regulations that may differ! * Optional or additional equipment WELGER RP 202 • RP 220 • RP 302 • RP 320...
- Page 93 (full address of the manufacturer - authorized representative established in the Community must also give the business name and address of the manufacturer) declare under our sole responsibility, that the product WELGER RP 202 / RP 220 / RP 302 / RP 320 ................................... (Make, model)